Aplicação do ciclo DMAIC para melhoria da qualidade em uma fábrica de boné

Abstract

With the increasing competitiveness and the need for continuous improvement in product and process quality, companies have been seeking to implement methodologies that reduce failures and waste, thereby increasing efficiency. One of the most effective methodologies in this context is Six Sigma, which serves as a strategic and statistical approach aimed at improving quality and reliability, providing organizations with competitive advantages. This study presents a field research conducted in a cap manufacturing factory, with the objective of identifying the root causes of product defects, rework, and variability among production batches. To achieve this, the DMAIC cycle (Define, Measure, Analyze, Improve, and Control) was applied as a structured approach for implementing quality improvement actions. Initially, the analysis focused on defects related to the cap brim stitching, which significantly impacted the final product quality and led to high rework rates. Based on the collected data, analyzed using p control charts, it became evident that the process was statistically out of control, exhibiting defective items and a proportion of defects influenced by special causes. By applying the Pareto Diagram and the Cause-and-Effect Diagram, the main causes of defects were identified. Subsequently, action plans were developed and implemented using the 5W1H tool, with solutions that included operator training, standardization of procedures, preventive machine maintenance, and stricter control of raw materials.